(One Step Setup) : A Strategy For Performance Excellence
(One Step Setup) : A Strategy For Performance Excellence
(One Step Setup) : A Strategy For Performance Excellence
Participant manual
Look Familiar ?
5S Elimination waste
Visual Mgmt Emphasis on visual techniques to manage process
Poka-Yoke Error proofing techniques
Spaghetti Chart
Kanban Material storage technique used to control process
Takt Time Determine pace or beat of a process
Std Work Evaluate tasks done during a process
SMED Single minute exchange of dies - Quick machine set up
TPM Integrate maintenance strategy with process
Cellular Flow Reduce inventory & cycle time through process layout and pull
production techniques
Expand
ExpandProcess
ProcessImprovement
ImprovementProgram
ProgramtotoUtilize
UtilizeKaizen
KaizenTool
ToolKit
Kit
Internal External
____________ ____________
____________ ____________
____________ ____________
Defective tooling,fixtures,
setup instruments are
noticed after the machine is •The operator notices that equipment is
missing after internal setup has begun.
turned on.
Setup Steps Setup Type Setup Type Resource Setup Type Setup Type
Traditional Traditional Consumption One-Step One-Step
Internal External ( %) Internal External
Preparation
X 20 % X
Establish Control
Settings X 15 % X
Process Improvement
X 10 % X
Separate Internal
from External Progressive
Reduction of Setup
Setup Enhancements Processes
Optimizing Setup
Integrate Internal into
Processes
External Setup
Step 6
Verification / Standardization
Section 1 Development of SMED “To Do” Plan: Establishment of the SMED team’s Action plan
identifying the specific actions required for each of the four (4) phases of SMED
implementation. Deliverable includes action plan and associated tasks with the SMED
implementation. 4
Section 2 Waste Identification Map: Identification of the 9 wastes associated with production of
products and services. A detailed map of each major work area is developed describing the
major types of wastes in each area. These wastes are the improvement opportunities that
exist prior to SMED.
The overall wastes is calculated for all the work areas and identified on the 9 Waste Radar
Chart 7
Section 3 SMED Action sheet: Establishing baseline key performance metrics in terms of key
deliverables, photographs, and current conditions of the “before” SMED implementation
phase. Deliverable includes the SMED action sheet. Please note: A video recording of the “
before” setup operation is recommended. 11
Section 4 Setup Process Map: A map showing the critical setup inputs, processes and outputs for
each machine/equipment setup operation.
14
Section 5 Standard Operation Setup Check-sheet: Identifies the setup operations and respective
process parameters required for an effective changeover. Also identifies resource
17
requirements for the setup operations previously identified.
Section 6 Setup Work Combination Sheet: Used to graphically display the amount on Internal and
External setup time within a changeover process for a particular machine. It further shows
21
tasks that are performed in series and parallel for further analysis.
Section 7 Setup Conversion Matrix: A matrix identifying the methodology for converting internal
setup operations into external setup operations.
24
Section 8 SMED Conversion “To Do”: An action list identifying specific setup improvement tasks for
each conversion opportunity identified in the “Setup Conversion Matrix”.
27
Section 9 Operational Control Plan: Procedure for setup operations AFTER setup improvements
have been made. This is a control plan to ensure consistent setup with the newly identified
setup parameters as a result of the SMED implementation. Includes visuals of setup tooling,
& supplies. 30
Section 10 Standard Visual Sign: Used to identify the machine, tooling, supplies, & inventory location
within the workplace. Shows the type of item, location of item, quantity of item, and the
34
preceding and following processes.
Section 11 SMED Status Report: Provides a format to compare improvement efforts between a
desired target and known starting value.
36
Section 12 Waste Identification Map: Identification of the 9 wastes associated with production of
products and services. A detailed map of each major work area is developed describing the
major types of wastes in each area. These wastes are the improvement opportunities that
exist prior to SMED.
9 Wastes Radar Chart: After the completion of SMED, the results of the waste reduction is
recorded, charted and compared to the initial 9 Waste Radar Chart. 39
S e c tio n 7
Setup Conversion Matrix
SET-UP CONVERSION MATRIX
Sheet
Date:
Page of
Area/Department Machine/Equipment Name Set-up Tools Required Operator Standard Set-up Time
Number
Date Prepared Minutes
When To Use The Setup conversion Matrix should be used after the Setup work
Combination sheet has been completed.
Who Should Use It The Setup conversion Matrix can be used by anyone involved in area or
process improvement.
Expected Benefits The resultant deliverables will be specific actions aligned with each of the
three conversion methodologies(Preparation of Setup Processes,
Combining Equipment Functionality, Standardized Jigs) to convert internal
setup operations into external setup operations.
How To Use It 1. Complete the sections titled “ Area/Department,
Machine/Equipment Name, Setup Tools required, Operator
Number, Date, and Standard Setup time.
3. Next list the total amount of Internal and External Setup time in the
appropriate column for each task Before any changes have been
made.
6. Finally add up the total internal and External setup times for both the
current and proposed columns and list these at the bottom of the
form in the sections titled “ Current Total & Improved Total “
respectively.
Next Step You are now ready to move to the next step, the SMED Conversion To Do
List.